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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/22—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material
  • B01J20/26—Synthetic macromolecular compounds
  • B01J20/261—Synthetic macromolecular compounds obtained by reactions only involving carbon to carbon unsaturated bonds
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
  • A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
  • A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
  • A61L15/42—Use of materials characterised by their function or physical properties
  • A61L15/60—Liquid-swellable gel-forming materials, e.g. super-absorbents
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/30—Processes for preparing, regenerating, or reactivating
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  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
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  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F2/00—Processes of polymerisation
  • C08F2/04—Polymerisation in solution
  • C08F2/10—Aqueous solvent
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F20/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride, ester, amide, imide or nitrile thereof
  • C08F20/02—Monocarboxylic acids having less than ten carbon atoms, Derivatives thereof
  • C08F20/04—Acids, Metal salts or ammonium salts thereof
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  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
  • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
  • C08F220/04—Acids; Metal salts or ammonium salts thereof
  • C08F220/06—Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
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  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J3/00—Processes of treating or compounding macromolecular substances
  • C08J3/02—Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques
  • C08J3/03—Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques in aqueous media
  • C08J3/075—Macromolecular gels
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  • C08J3/00—Processes of treating or compounding macromolecular substances
  • C08J3/12—Powdering or granulating
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  • C08J3/00—Processes of treating or compounding macromolecular substances
  • C08J3/24—Crosslinking, e.g. vulcanising, of macromolecules
  • C08J3/245—Differential crosslinking of one polymer with one crosslinking type, e.g. surface crosslinking
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  • C08J3/00—Processes of treating or compounding macromolecular substances
  • C08J3/24—Crosslinking, e.g. vulcanising, of macromolecules
  • C08J3/247—Heating methods
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  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
  • C08K5/0025—Crosslinking or vulcanising agents; including accelerators
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  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/04—Oxygen-containing compounds
  • C08K5/10—Esters; Ether-esters
  • C08K5/11—Esters; Ether-esters of acyclic polycarboxylic acids
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  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/04—Oxygen-containing compounds
  • C08K5/15—Heterocyclic compounds having oxygen in the ring
  • C08K5/151—Heterocyclic compounds having oxygen in the ring having one oxygen atom in the ring
  • C08K5/1515—Three-membered rings
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  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
  • C08L33/04—Homopolymers or copolymers of esters
  • C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
  • C08L33/062—Copolymers with monomers not covered by C08L33/06
  • C08L33/068—Copolymers with monomers not covered by C08L33/06 containing glycidyl groups
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J2220/00—Aspects relating to sorbent materials
  • B01J2220/50—Aspects relating to the use of sorbent or filter aid materials
  • B01J2220/68—Superabsorbents
• • C—CHEMISTRY; METALLURGY
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  • C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
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  • C08J2433/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
  • C08J2433/04—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters
  • C08J2433/06—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters of esters containing only carbon, hydrogen, and oxygen, the oxygen atom being present only as part of the carboxyl radical
  • C08J2433/08—Homopolymers or copolymers of acrylic acid esters
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/30—Sulfur-, selenium- or tellurium-containing compounds
  • C08K2003/3045—Sulfates
  • C08K2003/3081—Aluminum sulfate

Definitions

• the present disclosure relates to a super absorbent polymer exhibiting improved rewetting property and excellent absorption property, and a preparation method of the same.
• a super absorbent polymer is a type of synthetic polymeric material capable of absorbing 500 to 1000 times its own weight of moisture.
• SAM Super Absorbency Material
• AGM Absorbent Gel Material
• Such super absorbent polymers started to be practically applied in sanitary products, and they are now being widely used not only for hygiene products such as disposable diapers for children, etc., but also for water retaining soil products for gardening, water stop materials for the civil engineering and construction, sheets for raising seedling, fresh-keeping agents for food distribution fields, materials for poultices, or the like.
• the super absorbent polymer is widely used in the field of hygiene products such as diapers and sanitary napkins, and, for this purpose, it is necessary to exhibit a high absorption capacity for moisture and the like. In addition, it is necessary that the absorbed moisture should not leak out even under external pressure. Further, it needs to show excellent permeability by maintaining its shape even in an expanded (swelled) state after absorbing water.
• the hygiene products such as diapers and sanitary napkins may be subjected to pressure by the weight of a user.
• the super absorbent polymer applied to hygiene products such as diapers and sanitary napkins absorbs liquid and a pressure due to the weight of the user is applied to the absorbent polymer, a rewetting phenomenon and a urine leakage phenomenon in which some liquid absorbed in the super absorbent polymer is re-exuded may occur.
• the present disclosure provides a super absorbent polymer exhibiting improved rewetting property while having excellent basic absorption properties such as water retention capacity and absorption ability under pressure, and a preparation method of the same.
• the present disclosure provides a preparation method of a super absorbent polymer, including the steps of:
• the present disclosure also provides a super absorbent polymer, including:
• a super absorbent polymer exhibiting excellent absorption properties and suppressing a rewetting phenomenon and a urine leakage phenomenon can be provided.
• the present disclosure provides a preparation method of a super absorbent polymer, including the steps of:
• base resin or “base resin powder” means a polymer in the form of particles or powders obtained by polymerizing a water-soluble ethylene-based unsaturated monomer, typically an acrylic acid-based monomer of acrylic acid and/or its salt, followed by drying, pulverizing and classifying. It refers to a polymer in a state in which the surface modification or surface cross-linking step described below is not performed.
• the hydrogel polymer obtained by the polymerization reaction of the acrylic acid-based monomer is subjected to drying, pulverizing, classifying, surface cross-linking and the like, and is marketed as a powdery super absorbent polymer product.
• the super absorbent polymer obtained by the preparation method according to one embodiment of the present disclosure is superior in absorption properties such as water retention ability, absorption capacity under pressure and liquid permeability and kept dry even after being swollen with salt water, and it is possible to effectively prevent a rewetting phenomenon and a urine leakage phenomenon in which some urine absorbed in the super absorbent polymer is re-exuded. And the invention was completed.
• the internal cross-linking structure of the base resin and the super absorbent polymer including the same can be optimized by using the internal cross-linking agent with a specific combination and composition, and further, the cross-linking structure and gel strength of the surface cross-linked layer are optimized by using the polyvalent metal salt in the surface cross-linking to make the super absorbent polymer retain moisture once absorbed, despite the external pressure and the like.
• a monomer composition which is a raw material of the super absorbent polymer, including an acrylic acid-based monomer having at least partially neutralized acidic groups, the first and second internal cross-linking agents and a polymerization initiator, is first polymerized to obtain a hydrogel polymer, and then dried, pulverized and classified to prepare a base resin.
• the monomer composition which is a raw material of the super absorbent polymer includes an acrylic acid-based monomer having at least partially neutralized acidic groups and a polymerization initiator.
• the acrylic acid-based monomer is a compound represented by the following Chemical Formula 1: R 1 —COOM 1 [Chemical Formula 1]
• the acrylic acid-based monomer includes at least one selected from the group consisting of acrylic acid, methacrylic acid, and a monovalent metal salt, a divalent metal salt, an ammonium salt, and an organic amine salt thereof.
• the acrylic acid-based monomers may be those having acidic groups which are at least partially neutralized.
• the monomers may be those partially neutralized with an alkali substance such as sodium hydroxide, potassium hydroxide, ammonium hydroxide, or the like.
• a degree of neutralization of the acrylic acid-based monomer may be 40 to 95 mol %, 40 to 80 mol %, or 45 to 75 mol %. The degree of neutralization may vary depending on the final physical properties.
• An excessively high degree of neutralization causes the neutralized monomers to be precipitated, and thus polymerization may not readily occur, whereas an excessively low degree of neutralization not only deteriorates the absorbency of the polymer, but also endows the polymer with hard-to-handle properties, such as those of an elastic rubber.
• the concentration of the acrylic acid-based monomer may be 20 to 60 wt %, preferably 40 to 50 wt % based on the monomer composition including the raw material of the super absorbent polymer and a solvent, and properly controlled in consideration of polymerization time and reaction conditions.
• concentration of the monomer is excessively low, the yield of the super absorbent polymer may become low and economical efficiency may be reduced.
• concentration of the monomer is excessively high, there is a process problem that part of the monomers is precipitated, or pulverization efficiency is lowered upon pulverization of the polymerized hydrogel polymer, and the physical properties of the super absorbent polymer may be deteriorated.
• a polymerization initiator that has been generally used for preparing a super absorbent polymer can be applied without particular limitations.
• the polymerization initiator may be an initiator for thermal polymerization or an initiator for photopolymerization by UV radiation according to the polymerization method.
• the composition may additionally include the thermal polymerization initiator.
• any compound which can form a radical by light such as UV rays may be used as the photopolymerization initiator without limitation.
• the photopolymerization initiator may be one or more compounds selected from the group consisting of benzoin ether, dialkyl acetophenone, hydroxyl alkylketone, phenyl glyoxylate, benzyl dimethyl ketal, acyl phosphine, and ⁇ -aminoketone.
• benzoin ether dialkyl acetophenone
• hydroxyl alkylketone phenyl glyoxylate
• benzyl dimethyl ketal acyl phosphine
• acyl phosphine commercial Lucirin TPO, namely, 2,4,6-trimethyl-benzoyl-trimethyl phosphine oxide
• More various photopolymerization initiators are well disclosed in “UV Coatings: Basics, Recent Developments and New Application (Elsevier, 2007)” written by Reinhold Schwalm, p 115, and the present invention is not limited thereto.
• the concentration of the photopolymerization initiator in the monomer composition may be about 0.01 to about 1.0 wt %.
• concentration of the photopolymerization initiator is excessively low, the polymerization rate becomes slow, and when the concentration of the photopolymerization initiator is excessively high, the molecular weight of the super absorbent polymer becomes low and the properties may be uneven.
• one or more initiators selected from the group consisting of a persulfate-based initiator, an azo-based initiator, hydrogen peroxide, and ascorbic acid may be used.
• the monomer composition includes an internal cross-linking agent as a raw material of the super absorbent polymer.
• This internal cross-linking agent is for cross-linking the interior of the polymerized polymer of the acrylic acid-based monomer, that is, a base resin, and is distinguished from a surface cross-linking agent for cross-linking the surface of the polymer.
• a poly(meth)acrylate of polyols-based first internal cross-linking agent and a polyglycidyl ether of polyols-based second internal cross-linking agent are used in combination in a weight ratio of 1:20 to 1:300, 1:20 to 1:250, 1:22 to 1:245, or 1:25 to 1:240.
• the rewetting property can be further improved while maintaining excellent basic absorbency of the super absorbent polymer prepared by the above-mentioned method, for example, the water retention capacity and the absorption ability under pressure, and the absorption rate.
• the weight ratio of the first and second internal cross-linking agents is out of the range, the basic absorbency may be deteriorated or the rewetting property may not be improved.
• a poly(meth)acrylate of polyols-based compound for example, a poly(meth)acrylate of polyols-based compound having 2 to 10 carbon atoms can be used.
• a polyglycidyl ether of polyols-based compound having a polyfunctional epoxy group for example, a polyglycidyl ether of polyols-based compound having 2 to 10 carbon atoms can be used.
• a polyglycidyl ether of polyols-based compound having 2 to 10 carbon atoms can be used.
• at least one selected from the group consisting of ethyleneglycol diglycidyl ether, polyethylene glycol diglycidyl ether, glycerol polyglycidyl ether, propylene glycol diglycidyl ether and polypropylene glycol diglycidyl ether can be used.
• first and second internal cross-linking agents may be included at a concentration of 0.01 to 0.5 wt % based on the monomer composition, in combination, so that the polymerized polymer can be cross-linked.
• the monomer composition may further include a foaming agent, and/or a foam stabilizer.
• the foaming agent causes foaming during polymerization to form pores in the hydrogel polymer, thereby increasing the surface area.
• a carbonate can be used.
• sodium bicarbonate, sodium carbonate, potassium bicarbonate, potassium carbonate, calcium bicarbonate, calcium carbonate, magnesium bicarbonate or magnesium carbonate can be used.
• the foaming agent may be added at a concentration of 0.01 to 0.2 parts by weight based on 100 parts by weight of the acrylic acid-based monomer.
• the amount of the foaming agent is more than 0.2 parts by weight, the number of pores may become too large, gel strength of the super absorbent polymer may decrease and density may become low, which may cause problems in distribution and storage.
• the amount is less than 0.01 parts by weight, the function as the foaming agent may be insignificant.
• the foam stabilizer serves to uniformly distribute bubbles in the entire area of the polymer while maintaining the shape of bubbles formed by the foaming agent, which serves to increase the surface area of the polymer.
• an anionic surfactant may be used, and examples of the anionic surfactant include sodium dodecyl sulfate, sodium stearate, ammonium lauryl sulfate, sodium lauryl ether sulfate (SLES), sodium myreth sulfate, and alkyl-ether sulfate-based compounds similar thereto.
• the usable anionic surfactant is not limited thereto, but preferably sodium dodecyl sulfate or sodium stearate can be used.
• the anionic surfactant may be added at a concentration of 0.01 part by weight to 0.05 parts by weight based on 100 parts by weight of the acrylic acid-based monomer.
• concentration of the anionic surfactant is excessively low, the function as the foam stabilizer is insignificant and it is difficult to achieve the improvement of absorption rate.
• concentration is excessively high, water retention capacity and absorption rate during polymerization may be rather lowered, which is undesirable.
• the monomer composition may further include an additive such as a thickener, a plasticizer, a preservation stabilizer, an antioxidant, and the like, if necessary.
• an additive such as a thickener, a plasticizer, a preservation stabilizer, an antioxidant, and the like, if necessary.
• the raw materials such as the acrylic acid-based monomer having at least partially neutralized acidic groups, the photopolymerization initiator, the thermal polymerization initiator, the first and the second internal cross-linking agents, and the additive may be prepared in the form of a monomer composition solution dissolved in a solvent.
• any solvent which can dissolve the components may be used without limitation, and for example, one or more solvents selected from water, ethanol, ethyleneglycol, diethyleneglycol, triethyleneglycol, 1,4-butanediol, propyleneglycol, ethyleneglycol monobutylether, propyleneglycol monomethylether, propyleneglycol monomethylether acetate, methylethylketone, acetone, methylamylketone, cyclohexanone, cyclopentanone, diethyleneglycol monomethylether, diethyleneglycol ethylether, toluene, xylene, butyrolactone, carbitol, methylcellosolve acetate, N,N-dimethylacetamide, and the like may be used solely or in combination.
• the solvent may be included in the monomer composition at a residual quantity except for the above components.
• the method of preparing the hydrogel polymer by thermal polymerization or photopolymerization of the monomer composition is not particularly limited if it is a common polymerization method.
• the polymerization method is largely divided into the thermal polymerization and the photopolymerization according to the energy source of the polymerization.
• thermal polymerization it is generally carried out in a reactor having a kneading spindle, such as a kneader.
• photopolymerization it may be carried out in a reactor equipped with a movable conveyor belt.
• the polymerization method is just an example, and the present invention is not limited thereto.
• the hydrogel polymer obtained by carrying out the thermal polymerization by providing hot air to a reactor equipped with a kneading spindle such as a kneader or heating the reactor is discharged from the outlet of the reactor and may have a size of centimeters or millimeters, according to the shape of the kneading spindle installed in the reactor.
• the size of the obtained hydrogel polymer may vary according to the concentration and the feeding speed of the monomer composition, and generally the obtained hydrogel polymer may have a weight average diameter of about 2 to about 50 mm.
• the hydrogel polymer may be obtained in the form of a sheet having a width corresponding to a width of the belt.
• the thickness of the polymer sheet may vary according to the concentration and the feeding speed of the monomer composition, but it is preferable to feed the monomer composition so that a polymer sheet having a thickness of about 0.5 to about 5 cm can be obtained. It is undesirable to feed the monomer composition so that the thickness of the polymer sheet becomes excessively thin, because it makes the production efficiency low, and When the thickness of the obtained polymer sheet is over 5 cm, the polymerization reaction cannot evenly occur across the thickness because of its excessively thick thickness.
• the moisture content of the hydrogel polymer obtained by the above method may be about 40 to about 80 wt %.
• moisture content in the present disclosure is the content of moisture in the entire weight of the hydrogel polymer, and it means a value of which the weight of the dried polymer is subtracted from the weight of the hydrogel polymer.
• the moisture content is defined as a value calculated from the weight loss due to moisture evaporation from the polymer in the process of increasing the temperature of the polymer and drying the same through infrared heating.
• the drying condition for measuring the moisture content is that the temperature is increased to about 180° C. and maintained at 180° C., and the total drying time is 20 min including 5 min of a heating step.
• a coarse pulverizing step may be further performed before the drying step for increasing the drying efficiency, if necessary.
• the pulverizing machine used is not particularly limited. Specifically, it may be at least one selected from the group consisting of a vertical pulverizer, a turbo cutter, a turbo grinder, a rotary cutter mill, a cutter mill, a disc mill, a shred crusher, a crusher, a chopper, and a disc cutter, but it is not limited thereto.
• the hydrogel polymer may be crushed to have a diameter of about 2 to about 10 mm.
• the hydrogel polymer It is technically difficult to pulverize the hydrogel polymer to have a diameter of less than 2 mm because of its high moisture content, and there may be a phenomenon that the crushed particles cohere with each other. Meanwhile, when the polymer is crushed to have a diameter of larger than 10 mm, the efficiency enhancing effect in the subsequent drying step may be low.
• the hydrogel polymer pulverized as above or the hydrogel polymer immediately after the polymerization without the pulverizing step is subjected to drying.
• the drying temperature of the drying step may be about 150 to about 250° C.
• the drying time may become excessively long and the properties of the super absorbent polymer finally prepared may decrease.
• the drying temperature is higher than about 250° C., the surface of the polymer is excessively dried, and fine powders may be generated in the subsequent pulverization process and the properties of the super absorbent polymer finally prepared may decrease. Therefore, the drying process may be preferably carried out at a temperature of about 150 to about 200° C., more preferably at a temperature of about 160 to about 180° C.
• drying time may be about 20 to about 90 minutes in consideration of process efficiency, but it is not limited thereto.
• the drying method in the drying step is not particularly limited if it has been generally used in the drying process of the hydrogel polymer. Specifically, the drying step may be carried out by the method of hot air provision, infrared radiation, microwave radiation, UV ray radiation, and the like.
• the moisture content of the polymer after the drying step may be about 0.1 to about 10 wt %.
• the step of pulverizing the dried polymer obtained from the drying step is carried out.
• the polymer powder obtained after the pulverization step may have a diameter of about 150 to about 850 ⁇ m.
• a pin mill, a hammer mill, a screw mill, a roll mill, a disc mill, or a jog mill may be used as the pulverizer, but it is not limited thereto.
• a separate process of classifying the polymer powders obtained after the pulverization according to the particle size may be carried out.
• the polymer powders may be classified to have a constant weight ratio according to the particle size.
• the base resin After obtaining the base resin in the powder form through the above-described classification step, the base resin is heated in the presence of a surface cross-linking agent to carry out surface modification.
• a surface cross-linking solution containing a surface cross-linking agent is mixed with a dried, pulverized and classified polymer, that is, a base resin, and then the mixture is heated to carry out a surface cross-linking reaction of the pulverized polymer.
• the surface cross-linking step is a step of inducing a cross-linking reaction on the surface of the pulverized polymer in the presence of a surface cross-linking agent to form a super absorbent polymer having improved physical properties.
• a surface cross-linked layer (surface modified layer) is formed on the surface of the pulverized and classified polymer particles.
• surface cross-linking agents are applied on the surface of the base resin particles, so that surface cross-linking reactions occur on the surface of the base resin particles, which improves cross-linkability on the surface of the particles without substantially affecting the interior of the particles. Therefore, the surface cross-linked super absorbent polymer particles have a higher degree of cross-linking near the surface than in the interior, as the cross-linked polymer on the surface of the base resin is further cross-linked.
• the surface cross-linking agent is a compound capable of reacting with functional groups of the base resin.
• polyalcohol-based compounds, polyepoxy-based compounds, polyamine compounds, haloepoxy compounds, condensates of haloepoxy compounds, oxazoline-based compounds, or alkylene carbonate compounds may be used without particular limitations.
• polyalcohol-based compound may include one or more selected from the group consisting of di-, tri-, tetra- or polyethylene glycol, 1,3-propanediol, dipropylene glycol, 2,3,4-trimethyl-1,3-pentanediol, polypropylene glycol, glycerol, polyglycerol, 2-butene-1,4-diol, 1,4-butanediol, 1,3-butanediol, 1,5-pentanediol, 1,6-hexanediol, and 1,2-cyclohexane dimethanol.
• the polyepoxy-based compound may include ethylene glycol diglycidyl ether, glycidol and the like.
• the polyamine compound may include one or more selected from the group consisting of ethylene diamine, diethylene triamine, triethylene tetraamine, tetraethylene pentamine, pentaethylene hexamine, polyethylene imine, and polyamide polyamine.
• the haloepoxy compound may include epichlorohydrin, epibromohydrin, or ⁇ -methylephichlorohydrin.
• the mono-, di-, or polyoxazolidinone compound may include, for example, 2-oxazolidinone and the like.
• alkylene carbonate-based compound may include ethylene carbonate, and the like. These may be used alone or in combination with each other.
• the amount of the surface cross-linking agent added may be appropriately selected depending on the kind of the surface cross-linking agent added or the reaction conditions. However, the surface cross-linking agent may be generally used in an amount of about 0.001 to about 5 parts by weight, preferably about 0.01 to about 3 parts by weight, and more preferably about 0.05 to about 2 parts by weight, based on 100 parts by weight of the base resin.
• the amount of the surface cross-linking agent When the amount of the surface cross-linking agent is excessively small, the surface cross-linking reaction hardly occurs, and when the amount is higher than 5 parts by weight based on 100 parts by weight of the polymer, the absorbency such as water retention capacity may be deteriorated due to excessive surface cross-linking reaction.
• the surface cross-linking agent When the surface cross-linking agent is added, water may be further mixed together and added in the form of a surface cross-linking solution.
• water When water is added, there is an advantage that the surface cross-linking agent can be uniformly dispersed in the polymer.
• the added amount of water is preferably 1 to 10 parts by weight based on 100 parts by weight of the polymer in order to optimize a surface penetration depth of the surface cross-linking agent, while inducing even dispersion of the surface cross-linking agent and preventing the polymer powder from aggregating.
• the surface cross-linking step (surface modification step) described above may be carried out by using a polyvalent metal salt, for example, an aluminum salt, more specifically at least one selected from the group consisting of a sulphate, potassium salt, ammonium salt, sodium salt, and hydrochloride of aluminum, in addition to the above-mentioned surface cross-linking agent.
• a polyvalent metal salt for example, an aluminum salt, more specifically at least one selected from the group consisting of a sulphate, potassium salt, ammonium salt, sodium salt, and hydrochloride of aluminum, in addition to the above-mentioned surface cross-linking agent.
• the polyvalent metal salt may be added to the surface cross-linking solution together with the surface cross-linking agent, and may be used in an amount of 0.01 to 4 parts by weight, 0.05 to 1 part by weight, 0.1 to 0.5 parts by weight, or 0.15 to 0.3 parts by weight, based on 100 parts by weight of the base resin.
• the surface modification step is performed on the base resin by heating the mixture of the base resin and the surface cross-linking solution.
• the surface modification step may be carried out under well-known conditions depending on the kind of the surface cross-linking agent, for example, at a temperature of 100 to 200° C. for 20 to 60 minutes.
• the surface cross-linking agent is a polyvalent epoxy compound
• it may be carried out by heating at 120 to 180° C., or 120 to 150° C. for 10 to 50 minutes, or 20 to 40 minutes.
• the temperature of the surface modification step is less than 100° C. or the reaction time is too short, the surface cross-linking reaction may not occur properly and transmittancy may be lowered.
• the temperature exceeds 200° C. or the reaction time is too long, water retention ability may be lowered.
• the heating means for the surface cross-linking reaction is not particularly limited. It is possible to provide a thermal media thereto or provide a heat source directly thereto. At this time, usable thermal media may be a heated fluid such as steam, hot air, hot oil, and the like, but the present invention is not limited thereto. Furthermore, the temperature of the thermal media provided thereto may be properly selected in consideration of the means of the thermal media, heating speed, and target temperature of heating. Meanwhile, an electric heater or a gas heater may be used as the heat source provided directly, but the present invention is not limited thereto.
• a super absorbent polymer can be finally produced according to the method of one embodiment.
• This super absorbent polymer can exhibit improved rewetting property, excellent water retention ability, absorption ability under pressure and absorption rate, and the like, as it has an optimized internal cross-linking structure by using the specific internal cross-linking agents in combination.
• the super absorbent polymer prepared by the above method includes:
• the polyvalent metal salt such as an aluminum salt is optionally used in the surface cross-linking, so that the super absorbent polymer further includes a polyvalent metal salt formed on the surface cross-linked layer.
• This polyvalent metal salt such as an aluminum salt is already described above, and further explanation is omitted.
• the super absorbent polymer can basically exhibit absorption properties such as excellent water retention capacity, absorption ability under pressure and absorption rate.
• the super absorbent polymer may have water retention capacity (CRC) of 26 g/g or more, 27 g/g or more, or 30 g/g or more, and 40 g/g or less, 38 g/g or less, or 35 g/g or less, as measured according to EDANA method WSP 241.3.
• CRC water retention capacity
• the super absorbent polymer prepared according to the method above may have absorption ability under pressure (AUP) at 0.7 psi of 8 g/g or more, 10 g/g or more, or 11 g/g or more, and 30 g/g or less, 20 g/g or less, or 17 g/g or less, as measured according to EDANA method WSP 242.3.
• AUP absorption ability under pressure
• the super absorbent polymer prepared according to the method above may have a water-soluble component content of 10 wt % or less, 8 wt % or less, or 7 or less, and 0 wt % or more, 1 wt % or more, or 3 wt % or more, as measured according to EDANA method WSP 270.2.
• the super absorbent polymer prepared according to the method above may have a vortex time of 40 seconds or less, 38 seconds or less, or 35 seconds or less. Since the lower vortex time can be evaluated as the better, the lower limit is theoretically 0 seconds, but may be 5 seconds or more, 10 seconds or more, or 15 seconds or more.
• the vortex time refers to the time required (unit:second) for the vortex of the liquid to disappear due to the rapid absorption when the super absorbent polymer is added to physiological saline and stirred. It can be seen that the shorter the time, the faster the initial absorption rate of the super absorbent polymer.
• the super absorbent polymer can exhibit improved rewetting property while having excellent absorption properties. More specifically, the super absorbent polymer may have a rewetting property of 1.0 g or less, 0.9 g or less, or 0.8 g or less, and 0.1 g or more, 0.15 g or more, or 0.25 g or more.
• the rewetting property refers to the weight of water came out from the super absorbent polymer to the filter paper, after immersing 1 g of the super absorbent polymer in 100 g of tap water, swelling for 10 minutes, and leaving it on a filter paper for 50 minutes.
• the electrical conductivity of the tap water used in the measurement of the rewetting property may be in the range of 170 to 180 ⁇ S/cm, and the electrical conductivity may be measured using, for example, an electrical conductivity meter such as Orion Star A222 (manufactured by Thermo Scientific).
• Orion Star A222 manufactured by Thermo Scientific
• the electrical conductivity of the tap water has a great influence on the physical properties of the product, so the tap water having equivalent electrical conductivity should be used for the rewet measurement.
• the above-mentioned super absorbent polymer has excellent absorption characteristics, and the rewetting and urine leakage phenomenon can be reduced even when a large amount of urine is absorbed.
• an aqueous solution of the water-soluble unsaturated monomer (degree of neutralization: 70 mol %; solid content: 45 wt %) was prepared by adding 805.6 g of a 24.5% sodium hydroxide solution. When the temperature of the aqueous solution of the water-soluble unsaturated monomer became 45° C.
• a surfactant sodium dodecyl sulfate
• a surfactant sodium dodecyl sulfate
• the temperature of the aqueous solution reached 43° C., it was immersed in a container containing 0.15% of SBC and 0.12% of SPS, followed by irradiating with ultraviolet rays for 1 minute (irradiation amount: 10 mV/cm 2 ) to perform UV polymerization to obtain a hydrogel polymer.
• the obtained hydrogel polymer was pulverized into a size of 2 mm*2 mm, and the moisture content thereof was 40.1%.
• the obtained gel-type resin was spread on a stainless wire gauze having a hole size of 600 ⁇ m to a thickness of about 30 mm, and dried in a 180° C. hot air oven for 30 minutes.
• the dried polymer was pulverized using a pulverizer and classified with a standard mesh of ASTM standard to obtain a base resin having a particle size of 150 to 850 ⁇ m.
• a surface cross-linking solution containing 0.02 parts by weight of polyethylene glycol diglycidyl ester (EJ1030S) as a surface cross-linking agent, 8 parts by weight of water, 5 parts by weight of methanol, 0.05 parts by weight of sodium metabisulfite (Na 2 S 2 O 5 ) as a reductant and 0.2 parts by weight of aluminum sulfate was sprayed onto 100 parts by weight of the base resin and mixed. The mixture was put into a container equipped with a stirrer and a double jacket, and a surface cross-linking reaction was carried out at 140° C. for 30 minutes. Then, the surface-treated powder was classified with a standard mesh of ASTM standard to obtain a super absorbent polymer powder having a particle size of 150 to 850 ⁇ m.
• PEGDA 400 polyethylene glycol diacrylate 400
• EJ1030 ethylene glycol diglycidyl ether
• PEGDA 400 polyethylene glycol diacrylate 400
• EJ1030 ethylene glycol diglycidyl ether
• PEGDA 400 polyethylene glycol diacrylate 400
• EJ1030 ethylene glycol diglycidyl ether
• PEGDA 400 polyethylene glycol diacrylate 400
• EJ1030 ethylene glycol diglycidyl ether
• PEGDA 400 polyethylene glycol diacrylate 400
• EJ1030 ethylene glycol diglycidyl ether
• a super absorbent polymer powder was obtained in the same manner as in Example 1, except that aluminum sulfate was not used in the preparation of the surface cross-linking solution.
• physiological saline or salt water refers to a 0.9 wt % sodium chloride (NaCl) aqueous solution.
• the AUP at 0.3 psi of each resin was measured in accordance with EDANA WSP 242.3.
• a 400 mesh stainless steel net was installed in a cylindrical bottom of a plastic having an internal diameter of 25 mm.
• W 0 (g, 0.90 g) of the absorbent polymer was uniformly scattered on the steel net under the conditions of room temperature and humidity of 50%, and a piston which can provide a load of 0.7 psi uniformly was put thereon.
• the external diameter of the piston was slightly smaller than 25 mm, there was no gap between the cylindrical internal wall and the piston, and the jig-jog of the cylinder was not interrupted.
• the weight W 3 (g) of the device was measured.
• AUP (g/g) was calculated by using the obtained weight values according to the following Equation 2.
• AUP(g/g) [ W 4 (g) ⁇ W 3 (g)]/ W 0 (g) [Equation 2]
• the absorption rate (vortex) was measured in seconds in accordance with the method described in International Patent Application Publication No. 1987-003208.
• the water-soluble component content was measured in accordance with EDANA method WSP 270.2.
• the short-term rewetting property was measured by the following method. In the measurement of the rewetting property, tap water having an electrical conductivity of 170 to 180 ⁇ S/cm was used. The electrical conductivity was measured using an electrical conductivity meter of Orion Star A222 (manufactured by Thermo Scientific).
• Examples 1 to 3 exhibited the same water retention capacity, absorption capacity under pressure and absorption rate as those of Comparative Examples 1 and 2. It was also confirmed that they had much smaller amount of rewetting with respect to tap water than that of Comparative Examples, indicating improved rewetting property.
• Comparative Example 3 is about the super absorbent polymer prepared without using the polyvalent metal salt (aluminum sulfate) of the Example 1, and was confirmed to be poor in absorption ability under pressure and rewetting property as compared with Examples.

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